The fact that this part is able to be manufactured as one part is truly insane. I would think of maybe making a foam core part, and then doing a wet layup. Making a mold and doing prepreg layup is next level. The finish was perfect. I'm flabbergast.
I remember paying insane amounts of 1997 to 2000s money just for VHS video how to for basic composite work. Quickly found we needed equipment that was far too expensive to go too far into it. Also getting the raw materials weere insane back then as well. We used a ton of select products out of Florida as they were on of the few who would sell in "smaller" amounts. Fast forward 20 years and I run across your youtube channel. Filled in some gaps I had in my self paid for and learned training, and gave me a location to order small projects t amounts of raw material from. Here I am 5 years after that still eagerly devouring every video. It's funny, never heard of intensifiers, but would make wooden bucks to do the same process. That silicone would have been a massive time saver back then!
Previously we had a mold-less wing video where we were teased with a molded wing if there was enough interest. I feel like this video is the spiritual sequel to that video that we never got. Thank you so much for sharing the wisdom and I am already looking forward to whatever new videos you have in the pipeline
Thanks Austin. That moulded rear wing video is still on the whiteboard in the video planning room and I’m certain it will come along at some point. There are similarities with this process but also some techniques that are quite specialised to (downforce) wing construction so still well worth us doing I think. Thanks for watching!
The best part of this channel is its many dynamics with the viewers, even as the official company channel. On top of its expertise, easy-to-follow instructions, well-explained decision-making processes(arguably the most important ones in engineering), and constant focus on making the products and processes beginner and DIY friendly. I honestly could not find many flaws in you. *Edit: Oh, and all for free too!
Making an extremely difficult project look like it is just regular hard to do. 🥰 The perfection of the part is only exceeded by the perfection of the instruction. Seriously, the talent required to teach at this level needs to be talked about. Next level.
Another amazing video. A co-worker and I were complaining about the poor quality of RVs being made in the US. He suggested we start our own company and build something good. I told him we couldn't make them cheeply enough to make them light enough. That got me thinking about a full carbon fiber roof with AC and vent flanges molded in. Keep it light and the raised flange wouldn't leak.
Composites can certainly be very useful in RV construction. As you say, significant weight savings and advantages in reliability and function from integrated mouldings. We hope to do some larger scale projects like this on the channel in the future.
fiberglass is tougher than carbon fiber and is the go-to material for RV's and boats for that reason! I'm sure there's a market for less tough but lighter carbon fiber too
Absolutely amazing. This channel is just top tier in this industry. That's a lot of effort for a YT video and it shows... and this sort of info is normally guarded in the industry it seems.
Thanks, we really appreciate this feedback, and yes, there’s a lot of time and effort go into making this content but it’s something that we really want to do and enjoy doing.
“And my favourite part, the de-bagging” said no self taught amatuer ever. It goes one of two ways, pure joy at what you’ve produced or a pile of scrap ready for the bin.
Love it when the super experienced, talented guy hosting a channel "Easy Composites" ends the video by saying it's difficult and frustrating. More companies should post honest views...
Haha, yes, there were a few moments in this video, we could include them but maybe better to just acknowledge them at the end. The silicone intensifiers sticking the mould together took about an hour to separate, so we learned, fixed the method, and shared the benefit of our experience!
I think it’s absolutely amazing that we are able to watch this kind of insightful and well produced content for free. I love this channel and learning about this subject. I hope this channel thrives for a long time and that you guys can continue making great content. Thank you for making this. Best wishes for 2025!!!
Brings memories when I worked at a plastics factory vacuum forming certain polymers for aerospace and automotive industry. The most important job is for the pattern makers making moulds and jigs . The other snag working for a company that made hardstyling chavant clay very, very smelly place to work for still remember the secret formula that I know of by heart .
I think that the Silicone Intensifier Compound precisely addresses the issue I've been experiencing with some pieces I've been making. What I've been doing to minimize the bridging problem in my pieces is placing them under pressure for 24 hours with the mold open, which helps me eliminate bridging. However, I still always end up with some imperfections that I have to fix later. I believe the Silicone Intensifier Compound will solve all my problems. I will give it a try, but thank you in advance for the tutorial.
@@easycompositestv I want to see this. A bit like the SpaceX Falcon 9 landing bloopers reel. Although, I'd really like to see first the blooper and then the... rewind six hours... we did X and that was the problem. There's a lot of learning possible from mistakes, and it's way cheaper to learn from OTHER PEOPLE's mistakes!
If you’ve not watched our other vids on prepreg then yes, check it out. It’s not always the case that prepreg is best but for smaller, more intricate shapes like this then it generally is.
What a stunning looking airframe. ❤ Doofers is an appropriate name for those yellow things. Now you all know why these guys are mentioned by so many Tubers . Happy new year everyone. ☃️🎄
@@easycompositestv That would be great, I am currently designing a wing for my car and would like to see a wing tutorial for a smooth surface and trailing edge. I am unsure on how to do it. It would probably be a split mould with a lap joint in the front. But I am stuk on the trailing edge. Sandwiching the halves together (in my mind) could result in a longer tail or a weaker joint. If that makes sense haha Eagerly awaiting the video - Cheers!
OK, we’ll have a think about this. Hadn’t ever planned this drone to fly, but it could. There might be a good video in explaining the traditional hand layup technique for lightweight wings, so… watch this space!
Incredible job and it's beautiful. I really want to get back into flying drones, but all the stuff going on here in the US, its just not worth the headache
This is a gem, you guys are just awesome. I cannot thank you so much. I want to know if you can make a video using hand layup resin as prepeg are a bit hard to be stored and requires oven.
Yes, peel ply (which is what it’s called) can be used to prevent the need for keying before bonding, however, peel ply absorbs some resin and on such a thin laminate there’s no resin to spare and so you’ll end up with slightly dry reinforcement in those areas. On thicker laminated though, peel ply is a good time saver prior to secondary bonding.
Would love to also see the process of making the wings, which is what I presume we see in the background. Spread tow fabric, and I guess intensifiers used for the sharp trailing edge?
This is a very brilliant and educational video. But I have a question, Is it possible to use 3d printed parts as the "intensifier" (even if it may be sacrificial)? If so, which materials are suitable for this application?
What a good question! Honestly, we’ve not tried this but it could be possible. However, silicone is inexpensive (cheaper than 3D print, probably) and does the job so well (squishy, able to conform) that I think it’s unlikely that a 3D print would work as well. Possibly TPU, but the INTENSIL compound is so quick, easy and effective that unless you can’t get hold of some, it’s probably hard to beat with any kind of 3D print.
I have been wondering about using spray foam (for sealing cracks around doors, etc) with release backer sheet do create ( interior) mold form. I know Reynolds sells flexible expanding foams... your thoughts?
Sure, with a release film applied to the mould there's no reason why it wouldn't work, I would probably look at the 2-part foams rather than the stuff normally used in construction as they should be stronger. Thanks for watching!
Hi, great content as always from your side :) Do you plan or would be willing to show a video diving deep into a topic of Silicone Membranes for infusion process? Showing how to manufacture this would be a great value for fabricators which value high fiber to resin ratio but do not want to sacrifice time of closing the mold with standard bagging film.
I'm glad you wrapped with a discussion of the quantity of work, techniques, materials, and consumables that went into a 200-300g part. The result is stunning. Full stop. But the hours of skilled time and the many kilos of a wide variety of discarded plastic films, remnants, and sheet materials should be sobering for anyone wondering why the resulting drone would cost as much as a car.
Have you experimented with pouring closed cell foam? My assumption would be that it would expand under vacuum as the air pockets inside the foam expand. Applying pressure on the carbon.
That Intensil-stuff is exactly what I have been looking for! Thank you so much for sharing - I have a similar project with exactly the same issue at the trailing edge and this could very well be the solution to my issue. I thought about using a silicone bladder before - Maybe this is another video idea?
Silicone bladders are another topic that we’d certainly be happy to cover but if you’re dealing with a tight, slim area like a trailing wing then intensifiers, rather than a silicone bag, are likely to be the solution.
@@easycompositestv Yes, exactly, that was my impression, too. The bladder would not have been rigid or thin enough to properly get into those spots, but for larger and more complex internal shapes where access for removal after curing is limited, it still seems like the best solution. A video on bladders would be awesome!
Great video, as always ! I would love to see how the wing behind was made... Is it prepreg too ? How to get this good surface finish with the lighter 88 g carbon spreadtow prepreg ?
Really hope you go into the airfoils and their construction as well - as my little eye did spy what looked like one of the foils in the background 🙂 Now - I do have a set of rudder and mainfoils for our catamaran project to build. Those would be fully closed. What would be a good technique to lay those up wet and at the same time ensure both quality and structural integrity?
Haha! Sharp eye! For your project, I suspect the best process might be one we’ve not covered yet… foaming epoxy. We do plan on doing a video about foils (which are similar to this project in some ways, but different in others) in the near future.
@@easycompositestv Your stuff is great so looking forward to it - and of course I am a (small) customer and all your educational videos sure do educate me on what I need :-)
As always, thanks for the in depth video. But are you sure about the intensifiers not doing much work on their own? I was always told that the heat makes them expand. To the point where the type of silicone used to make them is important as some expand more than others - potentially putting a lot of force on the mold in the places they are being used. Is this wrong? Or is it that the material you are selling does not expand much with heat? Or that the geometry of the mold/part where the intensifiers may not be constrained enough and thus will just expand into an open space?
ahhh! carbon fiber drone... just the thing I learned about CF being electrically conductive and great at blocking RF signals.. lol.. I want a copy of that drone...
Thanks for another amazing tutorial. It's there any chance we could see some of the engineering side of the design process? Not the cad part, you've already demonstrated that (thanks), but the actual steps you take to decide on what laminate stack you're going to use?
How could these lap joints be achieved with dry layup and infusion? Would intensifiers work for infusion too? One of my concerns is that carbon fibre is electrically conductive, so it makes it impossible to use internal antennas in a drone. One could make the fuselage out of kevlar instead. Kevlar would also be beneficial for impact resistance. But that means either wet layup or infusion.
It was very excellent and professional. Are these fibers pre-impregnated with resin? Does it dry by air or heat? If it is already stained, how does it not stick to the hand?
This is prepreg carbon fibre so the resin is already in the reinforcement. Take a look at the related videos linked in the description, they explain the XC110 prepreg in full detail.
Yes, the shell does flex. No issue at all with that though, mainly the flat surfaces are aero skins; the fully assembled fuselage (with the internal structure added) is more than stiff enough for application. Remember, in aerospace, you want only the strength and weight that’s required, and no more!
@easycompositestv I absolutely agree with unnecessary weight staying on the ground. My primary concern on the flex is flutter induction. That style of flying wing is very sensitive to airflow delamination in the region on the root to motor mounting area. It's impossible to tell from the video if this is or isn't going to be a concern, just something to be mindful of should you take it to the next stage of flight. That's a lot of work to flat spin into the ground on your first flight. I'd hate to see/hear of that happening.
Amazing. Any chance of a video covering CNC machining of carbon fiber sheets? I've always avoided it due to safety concerns over breathing carbon dust and fibers.
We have a video (an old one!) about safety considerations when cutting carbon fibre. It is old but the information is still correct and relevant. It doesn’t directly talk about CNC machining but the considerations are the same. Additionally, we might do a video about CNC machining CF sheet because it’s a very useful thing to do.
for a one-off, is there an advantage in silicone enhancers over using something which does not cure? fabulous videos, forwarded the channel to our PR peeps as a target to shoot for (other industry)
Great video as always 👌... I've been wondering though. Why don't we see the traditional car (unibody) ,made from carbon ? Why does it always have to be a bathtub style monocoque ?
Babe, Babe !!! Wake up !! Easy Composites uploaded another masterpiece ! 🥰
Coming~!❤️
I do wonder how many thousands of Men Childs are watching this all over the globe and feeling stoked to see another part of the drone project!
@@BadYossa dozens of us.... DOZENS!
Don’t get your babe hard that quick might give him a heart attack
Love to see the finished drone
OK, noted! We might see if we can build this out into a finished bird in a future video.
@@easycompositestv PLEASE do it :)
@@easycompositestv ditto
same
The fact that this part is able to be manufactured as one part is truly insane. I would think of maybe making a foam core part, and then doing a wet layup. Making a mold and doing prepreg layup is next level. The finish was perfect. I'm flabbergast.
The lost metal casting he demonstrated might also work
that part is just stunning, every video I watch I get more impressed by y'all skills!!
@@nickb193 also by the innovations and technologies involved
Thanks Nick, yeah it did come out well, we'll be doing plenty more like this in the future! Thanks for watching!
This is truly a masterpiece by a master technician. We all have benefited from this and all your videos. Thank you for sharing.
Thank you. We genuinely appreciate feedback like this and don’t take it for granted 😀.
Very few people are probably going to take on a project this difficult, but I definitely enjoyed watching it! Good call putting it up.
Thanks. Genuinely it wasn’t the original plan but we do listen to feedback because we don’t always know what viewers will or won’t find interesting!
More videos! I absolutely love these tutorials . This information was guarded secrets 25 years ago when I first dabbled with composites on my own.
And 25 years ago when the Easy Composites founders (of which I’m one) started in composites!
I remember paying insane amounts of 1997 to 2000s money just for VHS video how to for basic composite work. Quickly found we needed equipment that was far too expensive to go too far into it. Also getting the raw materials weere insane back then as well. We used a ton of select products out of Florida as they were on of the few who would sell in "smaller" amounts.
Fast forward 20 years and I run across your youtube channel. Filled in some gaps I had in my self paid for and learned training, and gave me a location to order small projects t amounts of raw material from. Here I am 5 years after that still eagerly devouring every video.
It's funny, never heard of intensifiers, but would make wooden bucks to do the same process. That silicone would have been a massive time saver back then!
Previously we had a mold-less wing video where we were teased with a molded wing if there was enough interest.
I feel like this video is the spiritual sequel to that video that we never got.
Thank you so much for sharing the wisdom and I am already looking forward to whatever new videos you have in the pipeline
Thanks Austin. That moulded rear wing video is still on the whiteboard in the video planning room and I’m certain it will come along at some point. There are similarities with this process but also some techniques that are quite specialised to (downforce) wing construction so still well worth us doing I think. Thanks for watching!
@ be still my beating heart, there is still hope!
The best part of this channel is its many dynamics with the viewers, even as the official company channel. On top of its expertise, easy-to-follow instructions, well-explained decision-making processes(arguably the most important ones in engineering), and constant focus on making the products and processes beginner and DIY friendly. I honestly could not find many flaws in you.
*Edit: Oh, and all for free too!
TripAdvisor is over there
@ ngl it does feel like a 5 star hotel of a tech/fabrication channel, I hate to write it like tone of a tourist
Making an extremely difficult project look like it is just regular hard to do. 🥰
The perfection of the part is only exceeded by the perfection of the instruction. Seriously, the talent required to teach at this level needs to be talked about. Next level.
Thank you. We don’t take comments like this lightly. 🙏
So glad you are uploading more.. Best videos bar none..
Thank you. We don’t take feedback like this for granted.
your videos are top notch. whoever came up with making youtube videos and tutorials needs a raise!
It's a good day when a new video by Easy Composites comes out.
Another amazing video.
A co-worker and I were complaining about the poor quality of RVs being made in the US. He suggested we start our own company and build something good. I told him we couldn't make them cheeply enough to make them light enough. That got me thinking about a full carbon fiber roof with AC and vent flanges molded in. Keep it light and the raised flange wouldn't leak.
Composites can certainly be very useful in RV construction. As you say, significant weight savings and advantages in reliability and function from integrated mouldings. We hope to do some larger scale projects like this on the channel in the future.
fiberglass is tougher than carbon fiber and is the go-to material for RV's and boats for that reason! I'm sure there's a market for less tough but lighter carbon fiber too
Nice video, we usually use soft vacuum sealant tape instead of silicone, works like a charm.
you guys are at another level, prepreg is a complitely diffrent animal when i see videos of prepreg i feel like i dont know anything about composite
Absolutely amazing. This channel is just top tier in this industry. That's a lot of effort for a YT video and it shows... and this sort of info is normally guarded in the industry it seems.
Thanks, we really appreciate this feedback, and yes, there’s a lot of time and effort go into making this content but it’s something that we really want to do and enjoy doing.
This came exactly when needed for my hydrofoil project!! Much thanks from Canada.
“And my favourite part, the de-bagging” said no self taught amatuer ever. It goes one of two ways, pure joy at what you’ve produced or a pile of scrap ready for the bin.
This is awesome! I'm actually working on a composite UAV for my internship right now, so this is perfect timing
Love it when the super experienced, talented guy hosting a channel "Easy Composites" ends the video by saying it's difficult and frustrating. More companies should post honest views...
Haha, yes, there were a few moments in this video, we could include them but maybe better to just acknowledge them at the end. The silicone intensifiers sticking the mould together took about an hour to separate, so we learned, fixed the method, and shared the benefit of our experience!
Has transcended to a pure art form!
Haha! Thank you. Can’t tell you the hours (weeks, months!) that go into making 20 mins of video!
@@easycompositestvwe love it!
Wingfoil foils would be great.
I think it’s absolutely amazing that we are able to watch this kind of insightful and well produced content for free. I love this channel and learning about this subject. I hope this channel thrives for a long time and that you guys can continue making great content. Thank you for making this. Best wishes for 2025!!!
Thanks very much, we really appreciate feedback like this. And, for sure, we plan to keep making content like this, it’s what we love.
That is truly the best gift you can get between the Christmas and the New Year! :)
Thanks! It was a heck of a busy end of the year trying to get this ready for publication before we finished for a Christmas!
Great Inspiration. Thank you for educating people ! Greetings from Baltics.
Brings memories when I worked at a plastics factory vacuum forming certain polymers for aerospace and automotive industry. The most important job is for the pattern makers making moulds and jigs . The other snag working for a company that made hardstyling chavant clay very, very smelly place to work for still remember the secret formula that I know of by heart .
And what is the secret formula
@@yogamon Why do you want to know? .
I don't even work in this area but is so satisfying to watch the procedures and results!
This is the cleanest "homemade" part I've ever seen.
I think that the Silicone Intensifier Compound precisely addresses the issue I've been experiencing with some pieces I've been making. What I've been doing to minimize the bridging problem in my pieces is placing them under pressure for 24 hours with the mold open, which helps me eliminate bridging. However, I still always end up with some imperfections that I have to fix later. I believe the Silicone Intensifier Compound will solve all my problems. I will give it a try, but thank you in advance for the tutorial.
What a gorgeous part. This makes me want to get into the industry.
thats crazy clean workmanship, holy moly.
Superb! Thks for sharing these high level tutos. Happy new year to everybody!
Thanks, glad you’re enjoying them. Happy New Year to you too.
Awesome. I envy your surgically clean working environment and the videos that don't show all the b, s and t. Good, clean fun.
Haha, yes, well, as we all know, there is a hell of a lot of b, s and t to get to this point!
Kings of carbon tutorials nice one!
What a lovely presentation. Great video.
Thanks for the feedback 😀.
Brilliant technique, thanks for admitting you too learn the hard way sometimes!
Haha, more often than you’d think! Maybe we’ll do a video about the ‘hard yards’ some day!
@@easycompositestv I want to see this. A bit like the SpaceX Falcon 9 landing bloopers reel.
Although, I'd really like to see first the blooper and then the... rewind six hours... we did X and that was the problem.
There's a lot of learning possible from mistakes, and it's way cheaper to learn from OTHER PEOPLE's mistakes!
Definitely living up to the name of the channel
What a beautiful treat to a Sunday night!! ❤
Thanks bro. You’re always good for a banger
That is an absolutely beautiful part. Well done.
I already have the plane designed and I've been wondering how to start the project, this video is perfect
It was good timing then! Get in touch with our technical guys if you have any questions on the build.
very impressive work. those prepreg sheets seem very useful, way easier to work with and everything stays clean and tidy.
If you’ve not watched our other vids on prepreg then yes, check it out. It’s not always the case that prepreg is best but for smaller, more intricate shapes like this then it generally is.
The drone, looks like a very slick design!
Dude who does not even age, is again doing leisurely world’s best carbon fiber parts. Paul do you have Formula 1 background?
Amazing quality video as always!
I need part two for the drone to be finished, I'm really interested in seeing it fly
dream on that's not were this channel is about.....
Haha, well maybe we'll send it up in the new year! Thanks for watching guys!
@@easycompositestvhappy new year too bro
Pure gold! Thanks guys again!
Fantastic matte finish!!!
What a stunning looking airframe. ❤
Doofers is an appropriate name for those yellow things.
Now you all know why these guys are mentioned by so many Tubers .
Happy new year everyone. ☃️🎄
Thanks. Happy New Year to you too. It was a crazy panic getting this video ready for release!
You guys are always killing it
Haha, thank you. Each vid about 4 weeks in the making 😀.
Beautiful work as usual. Thanks.
Amazing video!
I am excited to see how the wings will be made.
Haha, OK, noted. Seems to be lots of interest in seeing the wings made so I think we’ll cover it soon.
@@easycompositestv That would be great, I am currently designing a wing for my car and would like to see a wing tutorial for a smooth surface and trailing edge.
I am unsure on how to do it. It would probably be a split mould with a lap joint in the front. But I am stuk on the trailing edge. Sandwiching the halves together (in my mind) could result in a longer tail or a weaker joint. If that makes sense haha
Eagerly awaiting the video - Cheers!
Gorgeous! Amazing work!
Thanks for the top notch information!
I freaking love geeking out on this stuff, thanks for the videos 🍻
You’re welcome, thanks for watching 😀.
This looks freakin' amazing! Oustanding work, man
Шикарное видео! Как всегда на этом канале.
Wow, that's quite a lot of skill demonstrated. We'd love to see the assembled drone flying and get some weight numbers
OK, we’ll have a think about this. Hadn’t ever planned this drone to fly, but it could. There might be a good video in explaining the traditional hand layup technique for lightweight wings, so… watch this space!
It's absolutely amazing. Would love to see the wing. Please show the full drone, including the maiden flight.
Incredible job and it's beautiful. I really want to get back into flying drones, but all the stuff going on here in the US, its just not worth the headache
I've always wanted to know how the little "step" around a drone hatch such as this one's canopy is made in the CAD software and in the mold.
awesome video , i was literally just starting my drone design for composites , this was very useful
Glad it helped you out, get in touch with our technical team if you need any help or advice on the project!
Man u r a real professional, thanks for all !
This is a gem, you guys are just awesome. I cannot thank you so much. I want to know if you can make a video using hand layup resin as prepeg are a bit hard to be stored and requires oven.
Brilliant video, mate. Keep up the great work.
Thanks for the feedback. Keeps us going!
may be using some anti-adhesion fabric in gluing places when curing and remove it right before gluing prevent from sanding?
Yes, peel ply (which is what it’s called) can be used to prevent the need for keying before bonding, however, peel ply absorbs some resin and on such a thin laminate there’s no resin to spare and so you’ll end up with slightly dry reinforcement in those areas. On thicker laminated though, peel ply is a good time saver prior to secondary bonding.
Would love to also see the process of making the wings, which is what I presume we see in the background. Spread tow fabric, and I guess intensifiers used for the sharp trailing edge?
Easy Composite: posts video.
Everyone: Oh what a day! What a lovely day!!
Haha, thank you. We certainly put everything we’ve got into these vids!
Great timing 👏
That’s a _curvy_ fuselage, I like it
Gorgeous part. We used to call those intensifiers, caul plates which wasn't 100% accurate, either.
Interesting, not called them called that before. Caul plates is sometimes what we’d call temporary barriers, in certain situations.
you have the best videos .very well made !
**NOW** it’s Christmas!
Merry Christmas Paul and all at EC.
This is a very brilliant and educational video. But I have a question, Is it possible to use 3d printed parts as the "intensifier" (even if it may be sacrificial)? If so, which materials are suitable for this application?
What a good question! Honestly, we’ve not tried this but it could be possible. However, silicone is inexpensive (cheaper than 3D print, probably) and does the job so well (squishy, able to conform) that I think it’s unlikely that a 3D print would work as well. Possibly TPU, but the INTENSIL compound is so quick, easy and effective that unless you can’t get hold of some, it’s probably hard to beat with any kind of 3D print.
@@easycompositestvThank you! I was thinking some odd shapes and corners where may be hard to apply the silicone properly.
Oh wow.
Thanks for the nice evening =)
I have been wondering about using spray foam (for sealing cracks around doors, etc) with release backer sheet do create ( interior) mold form. I know Reynolds sells flexible expanding foams... your thoughts?
Sure, with a release film applied to the mould there's no reason why it wouldn't work, I would probably look at the 2-part foams rather than the stuff normally used in construction as they should be stronger. Thanks for watching!
@@easycompositestv thanks for responding!
Hi, great content as always from your side :)
Do you plan or would be willing to show a video diving deep into a topic of Silicone Membranes for infusion process? Showing how to manufacture this would be a great value for fabricators which value high fiber to resin ratio but do not want to sacrifice time of closing the mold with standard bagging film.
Amazing job and product!
I am an Og follower since he had a beautiful long hair!
Haha! The Kayak repair vid! Also, lockdown 2020!
I'm glad you wrapped with a discussion of the quantity of work, techniques, materials, and consumables that went into a 200-300g part. The result is stunning. Full stop. But the hours of skilled time and the many kilos of a wide variety of discarded plastic films, remnants, and sheet materials should be sobering for anyone wondering why the resulting drone would cost as much as a car.
Beautiful work! When can we see it fly!?!
I just watched a 24 minute ad and I loved it
Have you experimented with pouring closed cell foam? My assumption would be that it would expand under vacuum as the air pockets inside the foam expand. Applying pressure on the carbon.
Thank you. This is relevant in Ukraine :)
Yes!
That Intensil-stuff is exactly what I have been looking for! Thank you so much for sharing - I have a similar project with exactly the same issue at the trailing edge and this could very well be the solution to my issue. I thought about using a silicone bladder before - Maybe this is another video idea?
Silicone bladders are another topic that we’d certainly be happy to cover but if you’re dealing with a tight, slim area like a trailing wing then intensifiers, rather than a silicone bag, are likely to be the solution.
@@easycompositestv Yes, exactly, that was my impression, too. The bladder would not have been rigid or thin enough to properly get into those spots, but for larger and more complex internal shapes where access for removal after curing is limited, it still seems like the best solution. A video on bladders would be awesome!
Great video, as always ! I would love to see how the wing behind was made... Is it prepreg too ? How to get this good surface finish with the lighter 88 g carbon spreadtow prepreg ?
Really hope you go into the airfoils and their construction as well - as my little eye did spy what looked like one of the foils in the background 🙂
Now - I do have a set of rudder and mainfoils for our catamaran project to build. Those would be fully closed. What would be a good technique to lay those up wet and at the same time ensure both quality and structural integrity?
Haha! Sharp eye! For your project, I suspect the best process might be one we’ve not covered yet… foaming epoxy. We do plan on doing a video about foils (which are similar to this project in some ways, but different in others) in the near future.
@@easycompositestv Your stuff is great so looking forward to it - and of course I am a (small) customer and all your educational videos sure do educate me on what I need :-)
As always, thanks for the in depth video.
But are you sure about the intensifiers not doing much work on their own? I was always told that the heat makes them expand. To the point where the type of silicone used to make them is important as some expand more than others - potentially putting a lot of force on the mold in the places they are being used. Is this wrong? Or is it that the material you are selling does not expand much with heat? Or that the geometry of the mold/part where the intensifiers may not be constrained enough and thus will just expand into an open space?
ahhh! carbon fiber drone... just the thing I learned about CF being electrically conductive and great at blocking RF signals.. lol.. I want a copy of that drone...
Thanks for another amazing tutorial.
It's there any chance we could see some of the engineering side of the design process? Not the cad part, you've already demonstrated that (thanks), but the actual steps you take to decide on what laminate stack you're going to use?
Hi Nicco, we do already have a lot of video ideas but this is another good one so I'll add it to the list, thanks for watching!
@easycompositestv thank you!
Do you still do this process for the wing given that it needs to have ribs and spars inside?
How could these lap joints be achieved with dry layup and infusion? Would intensifiers work for infusion too?
One of my concerns is that carbon fibre is electrically conductive, so it makes it impossible to use internal antennas in a drone. One could make the fuselage out of kevlar instead. Kevlar would also be beneficial for impact resistance. But that means either wet layup or infusion.
It was very excellent and professional. Are these fibers pre-impregnated with resin? Does it dry by air or heat? If it is already stained, how does it not stick to the hand?
This is prepreg carbon fibre so the resin is already in the reinforcement. Take a look at the related videos linked in the description, they explain the XC110 prepreg in full detail.
@easycompositestv thank you
Will we get to see how to make split molds for resin infusion and how to make parts in them?
Good question! And yes, you will. This video is somewhere near the top of our ‘planning board’!
20:31 looking like there's a lot of flex in the upper surface of the drone when cleanings?
Yes, the shell does flex. No issue at all with that though, mainly the flat surfaces are aero skins; the fully assembled fuselage (with the internal structure added) is more than stiff enough for application. Remember, in aerospace, you want only the strength and weight that’s required, and no more!
@easycompositestv I absolutely agree with unnecessary weight staying on the ground. My primary concern on the flex is flutter induction. That style of flying wing is very sensitive to airflow delamination in the region on the root to motor mounting area. It's impossible to tell from the video if this is or isn't going to be a concern, just something to be mindful of should you take it to the next stage of flight.
That's a lot of work to flat spin into the ground on your first flight. I'd hate to see/hear of that happening.
Thanks for the nice demonstration.
Btw, what is benefit to use yellow rubber stuff?
It pushes in tight areas where the vacuum bag doesn't easily get into.
Amazing. Any chance of a video covering CNC machining of carbon fiber sheets? I've always avoided it due to safety concerns over breathing carbon dust and fibers.
We have a video (an old one!) about safety considerations when cutting carbon fibre. It is old but the information is still correct and relevant. It doesn’t directly talk about CNC machining but the considerations are the same. Additionally, we might do a video about CNC machining CF sheet because it’s a very useful thing to do.
Thanks for watching, We did do one a few years ago, you can check it out here: ua-cam.com/video/j4lU3cVWTlo/v-deo.htmlsi=26lzsNjlcIxxwGSc
for a one-off, is there an advantage in silicone enhancers over using something which does not cure? fabulous videos, forwarded the channel to our PR peeps as a target to shoot for (other industry)
wait, was the wing you made high temp infused tooling for in a previous video also for this drone?
No, but well remembered! That wing was for a two section fixed wing VTOL, this one is a single section ‘flying wing’, so, fairly different formats.
Not quite the same, I'll have to make new moulds for the wings for this.
Great video as always 👌... I've been wondering though. Why don't we see the traditional car (unibody) ,made from carbon ? Why does it always have to be a bathtub style monocoque ?
Cost! Stamped steel is at least 1/20 the cost or cheaper